This paper reports the design, fabrication, and experimental characterization of a planar array of micro-fabricated electrospray emitters intended for space propulsion applications in micro-satellites. The engine uses the ionic liquid EMI-BF₄ as propellant. Electrospray engines take advantage of the electrohydrodynamic effect known as Taylor cone to produce thrust. The array is designed with an open architecture and it is composed of a set of spikes, i.e., emitters, coming out from a propellant pool. There are two configurations for the emitters: fully sharpened slender emitters, i.e., pencils, and truncated pyramidal emitters, i.e., volcanoes. The arrays have between 4 and 1024 emitters in an active area of 0.64 cm². The surface of the engine (tank and emitters) is covered with "black silicon" that acts as wicking material. The micro-fabrication of the engine is described. The paper reports experimental characterization of the hydraulics system including wettability tests, current/emitter-voltage characteristics, and imprints of the exit stream on a collector. Preliminary results demonstrating the feasibility of obtaining substantially larger emission currents at the same extraction voltage by controlling the temperature are also reported. The paper compares the experimental current/emitter-voltage characteristics with relevant theories of field emission of electrons

Additive manufacturing's attributes include print customization, low per-unit cost for small- to mid-batch production, seamless interfacing with mainstream medical 3D imaging techniques, and feasibility to create free-form objects in materials that are biocompatible and biodegradable. Consequently, additive manufacturing is apposite for a wide range of biomedical applications including custom biocompatible implants that mimic the mechanical response of bone, biodegradable scaffolds with engineered degradation rate, medical surgical tools, and biomedical instrumentation. This review surveys the materials, 3D printing methods and technologies, and biomedical applications of metal 3D printing, providing a historical perspective while focusing on the state of the art. It then identifies a number of exciting directions of future growth: ( a) the improvement of mainstream additive manufacturing methods and associated feedstock; ( b) the exploration of mature, less utilized metal 3D printing techniques; ( c) the optimization of additively manufactured load-bearing structures via artificial intelligence; and ( d) the creation of monolithic, multimaterial, finely featured, multifunctional implants.

Femtosecond ultrabright electron sources with spatially structured emission are an enabling technology for free-electron lasers, compact coherent X-ray sources, electron diffractive imaging, and attosecond science. In this work, we report the design, modeling, fabrication, and experimental characterization of a novel ultrafast optical field emission cathode comprised of a large (>100 000 tips), dense (4.6 million tips·cm^–2), and highly uniform (<1 nm tip radius deviation) array of nanosharp high-aspect-ratio silicon columns. Such field emitters offer an attractive alternative to UV photocathodes while providing a direct means of structuring the emitted electron beam. Detailed measurements and simulations show pC electron bunches can be generated in the multiphoton and tunneling regime within a single optical cycle, enabling significant advances in electron diffractive imaging and coherent X-ray sources on a subfemtosecond time scale, not possible before. At high charge emission yields, a slow rollover in charge is explained as a combination of the onset of tunneling emission and the formation of a virtual cathode.

The design, fabrication, and characterization of a new type of tactile display for people with blindness or low vision is reported. Each tactile element comprises a piezoelectric extensional actuator that vibrates in plane, with a microfabricated scissor mechanism to convert the in-plane actuations into robust, higher-amplitude, out-of-plane (vertical) vibrations that are sensed with the finger pads. When the tactile elements are formed into a 2D array, information can be conveyed to the user by varying the pattern of vibrations in space and time. Analytical models and finite element analysis were used to design individual tactile elements, which were implemented with PZT actuators and both SU-8 and 3D-printed scissor amplifiers. The measured displacements of these 3 mm × 10 mm, MEMS-enabled tactile elements exceed 10 µm, in agreement with models, with measured forces exceeding 45 mN. The performance of the MEMS-enabled tactile elements is compared with the performance of larger, fully-macroscale tactile elements to demonstrate the scale dependence of the devices. The creation of a 28-element prototype is also reported, and the qualitative user experience with the individual tactile elements and displays is described.

This study reports the first MEMS multiplexed coaxial electrospray sources in the literature. Coaxial electrospraying is a microencapsulation technology based on electrohydrodynamic jetting of two immiscible liquids, which allows precise control with low size variation of the geometry of the core–shell particles it generates, which is of great importance in numerous biomedical and engineering applications, e.g., drug delivery and self-healing composites. By implementing monolithic planar arrays of miniaturized coaxial electrospray emitters that work uniformly in parallel, the throughput of the compound microdroplet source is greatly increased, making the microencapsulation technology compatible with low-cost commercial applications. Miniaturized core–shell particle generators with up to 25 coaxial electrospray emitters (25 emitters cm⁻²) were fabricated via stereolithography, which is an additive manufacturing process that can create complex microfluidic devices at a small fraction of the cost per device and fabrication time associated with silicon-based counterparts. The characterization of devices with the same emitter structure but different array sizes demonstrates uniform array operation. Moreover, the data demonstrate that the per-emitter current is approximately proportional to the square root of the flow rate of the driving liquid, and it is independent of the flow rate of the driven liquid, as predicted by the theory. The core/shell diameters and the size distribution of the generated compound microparticles can be modulated by controlling the flow rates fed to the emitters.